Effects of additive manufacturing processes on part defects and properties: a classification review

Abstract

Additive manufacturing (AM) is an established manufacturing technology which allows for greater design freedom. Across the seven existing AM processes, we observe a variety of defects in printed parts, due to the different physical properties of each manufacturing process. This variety of defects complicates the design step without a clear overview of the deep interaction geometry-process-defect. The classification of these defects, which may be process-or machine-based, often raises methodological and terminological issues. In this paper, a review of AM general part defects using a process-based approach, is proposed. The aim of this paper is to provide the designer with a classification that would allow to make choices in the part design, by taking stock of the different defects affecting the resulting part considering the chosen process. For each process category defined in ISO/ASTM 52900, the main properties and defects of parts are reviewed and classified into four families: geometry and dimensions, surface quality, microstructure and mechanical properties. This review focuses in particular, on the process parameters which affect declined defects and properties allowing a relevant choice of the designer with respect to the process or the expected requirements of the part.

Enhancing Quality Control: Image-Based Quantification of Carbides and Defect Remediation in Binder Jetting Additive Manufacturing

“…This information enables them to refine their printing parameters, adjust material formulations, optimize post-processing techniques, and implement corrective actions to reduce the occurrence of defects in future prints. Defects like cracks, delamination, and dimensional inaccuracies can impact mechanical properties and surface finish [23]. Identifying these defects post-processing allows corrective measures such as heat treatment or surface finishing to meet quality standards.…”

“…Quality control is paramount in BJ-AM to produce high-quality components with precise dimensional accuracy and mechanical integrity [20,21]. According to statistical data, defects such as warping, deformation, rough surfaces, and low dimensional accuracy are prevalent in BJ printing processes, leading to suboptimal part performance [22][23][24]. For instance, studies have shown that porosity levels ranging from ~2.7% [25] to ~16.4% in BJ-printed components can significantly impact mechanical strength, thermal conductivity, and electrical conductivity [25][26][27].…”

“…Dini et al [35] emphasize BJ's binder injection and sintering processes; they tend to overlook broader defect categories originating from binder accumulation and penetration within the powder bed, such as bleeding and weak bonding. Similarly, Pastre et al [23] offer an initial review of defects encountered in BJ formation but provide a less comprehensive analysis primarily focusing on macro-scale defects. In another research, Parab et al [24] provided an enhanced understanding of the fundamental physics governing BJ processes using a high-speed synchrotron X-ray imaging technique, which is now poised to improve the quality of parts produced through BJ.…”

Analysing shrinkage compensation in additive manufacturing: a comparative study of reverse engineering and gauge-based methods

“…This contraction can vary unpredictably due to factors such as the thermal coefficient of the material, print orientation, layer height, and cooling rates, leading to dimensional inaccuracies in the final product (Fitzharris et al, 2018). The repercussions of shrinkage are multifaceted, influencing not only the geometric fidelity but also the mechanical performance and assembly compatibility of the parts (de Pastre et al, 2022). For industries where precision is not just a quality marker but a critical requirement (e.g., aerospace, biomedical implants, and precision engineering) the repercussions of shrinkage are not merely a limit but a barrier to application (Srivastava and Rathee, 2021).…”

Manufacturing Process, Tensile-Compressive, and Impact Properties of Tungsten (W)-Particle-Reinforced SLA Methacrylate

“…Among production processes, additive manufacturing solutions offer several advantages, particularly fast production from a CAD design file [ 1 , 2 ] to the final product and the possibility of producing near-net-shape complex geometries without additional operations while avoiding material waste [ 2 ]. Additive manufacturing includes different technologies and diversifies from polymer, ceramics, and metallic materials [ 3 , 4 , 5 ].…”